Self-Heating Porous Catalyst Module for Harmful Gas Removal
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Solution Overview
Problem
Existing technologies for removing harmful gases and ozone are inefficient, require external heating, and are not suitable for miniaturization or low-energy applications, often necessitating large-scale facilities and periodic replacement of catalysts, while also producing residual ozone that is harmful.
Innovation Solution
A catalyst module with a self-heating, porous heating carrier and multiple catalyst layers that promotes decomposition reactions, eliminating the need for external heating and allowing for compact, cost-effective removal of harmful gases and ozone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external heating is used to activate the catalyst, then the catalyst can reach operating temperature, but energy loss increases and device complexity increases
Solution Approach 1:
The heating function and catalytic reaction function are merged into a single integrated catalyst module. The heating carrier serves dual purposes: it provides the necessary thermal energy to activate the catalyst and also acts as the support structure for the catalyst layers, eliminating the need for separate external heating devices and reducing energy loss.
Solution Approach 2:
The catalyst module is designed to self-heat through the exothermic catalytic reactions themselves. Once initiated, the heat generated by the decomposition reactions of harmful gases and ozone maintains the catalyst at its operating temperature, creating a self-sustaining system that does not require continuous external energy input.
2Productivity
If large-scale facilities are used for harmful gas removal, then removal efficiency is sufficient, but the system cannot be miniaturized for indoor use
Solution Approach 1:
The heating carrier is designed with a porous structure that provides an extremely large internal surface area relative to its external dimensions. This allows a significant amount of catalyst to be distributed throughout the compact structure, maintaining high removal efficiency while enabling miniaturization for indoor applications.
Solution Approach 2:
The catalyst is distributed in three-dimensional space within the porous carrier structure rather than being confined to a two-dimensional surface. This dimensional utilization maximizes the catalyst-gas contact area within a small volume, achieving high productivity in a compact form factor.
3Reliability
If periodic replacement of catalysts is implemented, then catalyst activity is maintained, but operational continuity is interrupted and maintenance complexity increases
Solution Approach 1:
The catalyst module is designed for continuous operation without interruption. The heating carrier structure and catalyst formulation are engineered to maintain stable performance over extended periods, eliminating the need for periodic replacement and ensuring uninterrupted harmful gas and ozone removal.
4Productivity
If high temperature heating is used to decompose ozone, then ozone removal is effective, but energy consumption increases and temperature control becomes complex
Solution Approach 1:
The catalyst formulation and heating carrier properties are optimized to enable ozone decomposition at lower temperatures than conventional methods. By changing the operational temperature parameter from high (300°C or more) to a moderate range, energy consumption is significantly reduced while maintaining effective ozone removal.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient, low-cost, and miniaturized removal of harmful gases and ozone, with rapid temperature control and reduced energy loss, effectively processing gases at room temperature without additional adsorbents.
Implementation Method 1
an oxidation reaction or reduction reaction of harmful gas is carried out in a self-heating heating carrier
Implementation Method 2
a catalyst region formed on at least a portion of the surface of the heating carrier including the flow channels and containing a catalyst material for promoting a decomposition reaction of harmful gas
Implementation Method 3
having a porous structure with pores
Data Source
AI summary
The present disclosure provides a catalyst module for removing harmful gas, wherein an oxidation reaction or reduction reaction of harmful gas is carried out in a self-heating heating carrier. According to an embodiment of the present disclosure, the catalyst module for removing harmful gas comprises: a heating carrier composed of an electrically heatable heating body, including one or more flow channels inside, and having a porous structure with pores; and a catalyst region formed on at least a portion of the surface of the heating carrier including the flow channels and containing a catalyst material for promoting a decomposition reaction of harmful gas passing through the flow channels, wherein the catalyst region comprises: a first catalyst layer having a first catalyst material loading amount in the pores of the heating carrier; and a second catalyst layer applied on the inner surface of the heating carrier and having a second catalyst material loading amount higher than the first catalyst material loading amount.